As many of you already know, Don Post Studios is no longer making Star Wars helmets and masks. Rubie's is now gearing up to sell licensed Star Wars helmets and masks of their own, including the Royal Guard helmet. The latest information I've heard is that Rubie's will begin selling them later this year. The following instructions assume you are modifying a DP helmet. We will all have to wait and see if the Rubie's helmets require different modifications. As for the DP helmet, its a shade or two off of the bright cimson color of the screen used helmets.
Image 1 - Here is my DP helmet after removing the visor and sanding the surface.
Image2 - Here is my helmet after sanding, priming, and repainting.
First I sanded down the surface of the helmet to help the primer adhere to the surface. Next I used automotive body/scratch filler to fill in the Don Post copyright markings, as well as whatever nicks and scratches on the helmet.
Then I applied two coats of white, sandable primer; waiting 24hrs between coats to allow them to dry thoroughly. I also lightly sanded the primed surface after both primer coats.
Next I applied two coats of Krylon "Banner-Red" spray paint, again allowing 24hrs between coats for the surface to dry thoroughly.
Finally I applied two coats of Krylon high-gloss clear coat, taking great care to remove any dust or debris from the helmet before starting. Again, I allowed 24hrs between each coat (just to be safe).
The biggest problems with actually wearing the helmet in costume are vision impairment and lack of ventilation. I modified my helmet's visor aperture to make it wider and replaced the red visor with one i cut out of a cheap motorcycle visor, which greatly improved visibility through the aperture, but didn't alleviate the problem of my exhalation fogging it up.
To remedy the fog problem, I began using a long, flexible plastic tube as a breathing apparatus, and made 4 small ventilation cuts in the sides of the helmet. By exhaling through the tube, and inhaling through my nose, cool air was drawn into the helmet and against the visor.
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